EP0895894B1 - Part of an automobile with a flocked lining and procedure for flocking such a part - Google Patents

Description

The present invention relates to the realization of coatings for vehicle interior components automobiles by the flocking technique. Such coatings can be used in particular for seat components, such as seats or backrests, armrests, headrests, or only part of these elements but also for other internal elements of cars, such as certain interior walls or the dashboard for example.

It is recalled that, in general, the flocking technique consists in applying on a support adhesive of more or less long fibers, of a material such as wool, cotton, or synthetic fibers, called flock. The support thus coated has an aspect velvety, resulting from the general orientation of the fibers perpendicular to the surface of the support. A method known flocking consists in applying to the support a layer of adhesive on which the fibers are deposited by means of a flock distributor, the distribution of fibers being obtained through the establishment of a field between the said distributor and the support, this field to attract fibers to the support and their anchoring on the adhesive layer with the desired orientation.

We already know, in particular by documents FR-A-2708843 (corresponding to the preamble of claim 1), FR-A-2709050 and FR-A-2709051, a method of flocking of fragile supports, such as upholstery molded or cut foam for furniture or to the automobile, according to which it is planned to strengthen the resistance of the surface of these supports by a layer intermediate of an elastomeric material, this layer intermediate which can itself constitute the adhesive for flocking fibers. This process aims to obtain a better resistance of the flocked product to abrasion and tears, as well as improving the surface appearance, especially in the case of a cut foam support or molded, the surface of which may be grainy or present roughness. It also aims to allow flocking carved surfaces or undercut shapes or against clearance.

The present invention aims at the same results, but with a reduced cost and a simplification of the process, and also aims to give a particular aspect to the flocked surface.

With these objectives in view, the object of the invention is a motor vehicle element having a body and a flocked exterior coating, said coating being made of flock held on the surface of the body by an adhesive film, characterized in that it comprises a fine textile veil covering the said surface and adhering on it, and the flock covers the said textile veil.

This veil can be a knitted or woven fabric, or nonwoven, suitable for marrying by local elongation three-dimensional shapes of the surface. Typically, we will use a synthetic textile, such as by example in polyamide or polyester.

The invention is particularly applicable to flocking parts whose body is made of a deformable material, compressible, such as for example synthetic foam, flexible polyurethane foam molded or cut, or polyester fibers, latex hair, or any other foam, alveolar or not. In these applications, an advantage particular of the textile veil is that it strengthens the resistance of the part, in particular its resistance to tears, while retaining its original flexibility. In Indeed, the aforementioned foams, commonly used by example as seat padding, present the disadvantage of tearing relatively easily when subjected to stresses, such as those which can be exerted on the surface following a charge located, for example under the weight of the user of the seat, or simply due to friction that may occur occur during user movements. It is one of the reasons why classically these padding or padding are covered with fabric, velvet, leather, or similar. The installation of such coatings is sometimes delicate, because it is necessary to ensure the maintenance of the coating on the padding, which either requires the use of hanging systems covering on the seat frame, i.e. gluing the coating on the foam padding. In addition, the preparation of these coatings requires operations cutting and sewing to give them a shape suitable for covering of the various seat elements. All this therefore involves significant costs. The invention allows these costs to be reduced by carrying out the coating of finishing of these seat elements by flocking, without however adversely affect resistance, thanks to the reinforcement provided by the textile veil whose fibers, which extend generally parallel to the surface and adhere to these, limit the risk of tearing initiations.

In addition, this veil, which is stretched over the piece, smooths out small surface defects in padding, such as asperities caused when cutting blocks foam, or hollow resulting from bubbles generated during their molding.

Although the invention is therefore particularly advantageous for flocking foam parts relatively flexible, it can also be applied to parts with greater rigidity, such as padding in rigid foam or other materials conventionally used for example for parties side of seats, door frames, or any other car interior element capable of receiving a velvety appearance coating.

Whatever the case, the textile veil allows more to give the flocked surface a texture look corresponding to that of the veil used, for example a woven appearance when the veil is woven.

Preferably, the textile veil is fixed on the surface of the element flocked with glue which ensures also maintaining the flock. The veil thus constitutes a sort of reinforcement intimately linked to the glue film, and therefore both to the body of the element and to the flock fibers, and this by doing only one glue.

The invention also relates to a method of flocking of a motor vehicle element, according to which we paste the surface of a body of said element then we projects flock onto the glued surface, this process being characterized in that, before gluing, it is coated the surface of the body of a fine textile veil.

According to a particular provision, the veil textile is kept stretched on the surface by tension rods forming a frame surrounding the contours of the surface to be flocked.

According to another particular provision, intended flocking of elements having a shaped body annular, a tubular textile veil is used, which we pass through the opening of the body and we fold around the peripheral surface of said body.

According to yet another provision, for the flocking elements with a body having contours convex, we fix the textile veil on a frame of dimensions greater than that of the surface to be flocked and we apply the veil on the surface of the body by pushing the frame around the body.

Other characteristics and advantages will appear in the description which will be made of different modes for carrying out the flocking method according to the invention, adapted according to the shapes of the elements to be coated.

• les figures 1 à 4 illustrent les différentes étapes du flocage d'un élément de siège de forme générale parallélépipèdique, tel que par exemple un coussin de siège ou un appuie-tête plein,
• les figures 5 à 8 illustrent une première méthode de mise en place du voile textile pour le flocage d'un appuie-tête ajouré,
• les figures 9 et 10 illustrent une deuxième méthode utilisable pour le flocage d'un tel appuie-tête, ou d'une pièce ayant une forme en creux.

Reference is made to the accompanying drawings, in which

• FIGS. 1 to 4 illustrate the different stages of flocking a seat element of generally parallelepiped shape, such as for example a seat cushion or a full headrest,
• FIGS. 5 to 8 illustrate a first method of fitting the textile web for flocking an openwork headrest,
• Figures 9 and 10 illustrate a second method usable for flocking such a headrest, or a part having a hollow shape.

In FIG. 1, a block of foam 1 has been represented, for example in polyurethane foam, constituting the body of the manufactured part, as well as a piece of textile veil 2. Veil 2 is presented, slightly stretched, on block 1. We then place on the veil a support frame 3 of corresponding dimensions to those of the outline of the block, and we push this frame around from block 1 so apply the veil with a certain tension, as shown in figure 2. Thanks to the flexibility of the veil and its deformation capacity, it applies uniformly to the surface of the block, without wrinkling. Frame 3 can be kept in the position represented simply by wedging around of the block, or by mechanical holding means annexes, not shown.

We then glue, as shown Figure 3, by spraying a conductive adhesive 4 to by means of a pistol 5. The adhesive is therefore applied to the veil but also infiltrates through it to adhere to the surface of the block.

Flocking is then carried out, in a manner known in self, by projecting the flock fibers 6 onto the surface previously glued, using a field electrostatic set up between flock distributor 7 and the conductive glue film.

When the flocking is finished and the glue is taken, we remove the frame 3, and we can then cut the circumference in excess of the veil, or fold it upside down of the room.

To prevent frame 3 from becoming stuck to the piece and also flocked, on the one hand, we will cover beforehand as part of a protective layer, and more, we will realize this frame in a material not conductor, to prevent the flock from also coming cover it.

In the following two examples, gluing and flocking are made in a similar way to what comes to be explained. We will therefore only describe the implementation place and maintenance of the veil and the means used to this effect.

Figure 5 shows schematically a headrest openwork 11. The textile veil used in this case is present in the form of a tubular veil 12. This veil is inserted in hole 13 of the headrest then tensioned and folded around the headrest as seen in Figures 6 and 7, this being possible thanks to the large capacities of deformation of the veil. Its elasticity makes the veil applies perfectly against all sides inside and outside of the headrest. The upkeep veil is then provided on the back 14 of the headrest, as shown in Figure 8, for example by a rod 15 wedged in a groove 16 formed at this effect in the said reverse side 14.

Figures 9 and 10 illustrate another method of maintaining the veil on an openwork piece 21. In this variant, the part 21 is placed on a support 29. For maintain the veil around the part, we use a frame 23 provided with pins 24 which grip the web 2, which is here a plane veil as in the mode of realization of FIGS. 1 to 4, the frame 23 being pushed around part 21, then kept pressed against the support 29, as shown in FIG. 10, by rods thrust 25. The veil may also be claimed on the frame and maintained thanks to the pins 24. Furthermore, using a punch 26 of dimensions corresponding to those of the central opening of the room to push the veil in this hole, so as to apply it against the walls of said orifice. We then glue and the flocking as indicated previously.

The invention is in no way limited to the modes of carrying out the flocking process, or flocked objects, which have been described above only as examples. In particular, the flocking according to the invention can be used not only on any room or any part of a room with flat surfaces or convex, but also on concave surfaces, in the since the particular shape of such surfaces allows to apply and maintain the textile veil there during gluing and flocking.

Claims (10)

1. Element of an automobile which has a body (1, 11, 21) and a flocked exterior covering, the said covering consisting of flock held on the surface of the body by a film of adhesive, characterised in that it includes a fine textile gauze (2, 12, 22) covering the said surface and adhering thereto, and the flock covers the said textile gauze.
2. Element of a vehicle according to Claim 1, characterised in that the gauze is fixed on the surface of the element by the glue which also ensures retention of the flock.
3. Element of a vehicle according to Claim 1, characterised in that the textile gauze is a knitted or woven or non-woven textile capable of following three-dimensional shapes of the surface by localised elongation.
4. Element of a vehicle according to Claim 3, characterised in that the textile gauze is made from synthetic material.
5. Element of a vehicle according to Claim 1, characterised in that the body is made from synthetic foam.
6. Element of a vehicle according to Claim 1, characterised in that it constitutes a seating element.
7. Method of flocking an element of an automobile, according to which the surface of a body (1, 11, 21) of the said element is glued, then flock (6) is projected onto the glued surface, characterised in that before the glueing the surface of the body is covered with a fine textile gauze (2, 12, 22).
8. Method according to Claim 7, characterised in that the textile gauze is kept stretched on the surface by tension rods (3, 23) surrounding the contours of the surface to be flocked.
9. Method according to Claim 7, for the flocking of elements having a body (11) of annular shape, characterised in that a tubular textile gauze (12) is used which is passed into the orifice (13) of the body and is turned back around the peripheral surface of the said body.
10. Method according to Claim 7, for the flocking of elements having a body (21) with convex contours, characterised in that the textile gauze (22) is fixed on a frame (23) having dimensions greater than those of the said surface and the gauze is applied to the surface of the body by pushing the frame around the body.

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